1985 L/R 90 2.5 petrol into something Mo better

[tomaco1]

I must Back-track a bit, I've had the truck just over a year, and spent just about ?????????? dollars!

A wise man once told me not to keep track of Money Spent!

As a side note, I am pretty much a novice, but am fortunate enough to work in a Vocational school, with access to Mechanics and work shops.


Bought it last Novermber as pretty much a stock 1985 90. Had a 2" lift, and that's about it.

Before and after!

The Final Mods will be 200tdi and a paint job.

Follow-up Post:

Not counting my trip to Gary, but lets not talk about that!

I believe the first project I did was to replace the the rear floor and remove the Jumpseats.
The floor was rotted and patched with some type of fiberglass.
I pulled the floor out and replaced it with a new piece of aluminium.
I also needed to replace the the stringers(front to back) I used aluminium I got at the hardware store and I had welded to match.

I later used quitecar on the inside of the truck which you see on the 2nd and 3rd pics, and removed the Bulk head.

[Bozman]

Looks great Tom. Left hand drive too, what a bonus.

Keep the pics coming!

[tomaco1]

Thanks

Follow-up Post:

Big JOB!

Thanks to this site I realized I had no overhead protection, "Roll Bar"
Studied up, got in touch with Ron and was able to swing through Boston on my From Newport to L.I. big Detour.
I was on the fence until I realized that I got that cool Outside bar! I told you I was new to this.
Cut the holes in the wings, got the A-pillar supports from Safari Rover, removed the Bulkhead, had some b-pillar supports fabricated by a local welder, and wrestled with it for 3 days. wool-a, it was in!
The SW rollbar was pretty much perfect, by the way. Totally changed the look of the truck.

[130Tdi]

Tom,

What do you think of the quiet car ? Big difference or negligible ?

[tomaco1]

I noticed a big difference, but I had no headliner and sprayed the roof.

Follow-up Post:

Swapped out the bumper for an equipe, upgraded the lights, and took out the old school A/C grill.

And Doug, the QuiteCar also seems to be really durable. Its even held up under the front matts where its constantly wet.

Excuse the Hound, she's fiendin for those Costco Chickens!

[TDI Guy]

Looks Great.

[evilfij]

The pewter colored boosts really look sharp. I also like the "desert pink" color.

Ron

[tomaco1]

Its "roan brown" code name "Poo Brown" but will be painted soon.

[Stmpede]

It's lookin' good Tom. What color are you painting it?

[tomaco1]

Thanks, I haven't decided on color yet.

Follow-up Post:

A Green, or a blue I'm thinking.


We had a Scion in one of our shops, It was a little like the Arles.

The other I just found on yhe Scion site. I think both colors would look much better on a 90.


MAYBE NOT

[cabell]

I'm with Ron on the wheels, I really like the look. What did you do to 'em?

[Stmpede]

Looks good Tom, but its so close anyway, why not just go with Arles and use a factory color? BTW, I like the wheels as well. It looks like your really making some nice changes!

[tomaco1]

I was a powder coat with a texture, i forget exactly what its called.

[TDI Guy]

what does it cost to do a set of rims? Did you just bring them to a local powder coater?

[tomaco1]

Its Pricey, They say $65 a wheel. But they do have to media Blast them, and then powder coat them. My school just go a powder coating set-up( a year to late ), so I've seen first hand how the costs builds up.

[JSBriggs]

Thanks, I haven't decided on color yet.

Follow-up Post:

A Green, or a blue I'm thinking.


We had a Scion in one of our shops, It was a little like the Arles.

The other I just found on yhe Scion site. I think both colors would look much better on a 90.


MAYBE NOT

Land Rover had some nice blues. Marine, Arles, and my favorite if RAF blue from the Series 1 107's

http://www.beadell.com.au/images/107%20inch.jpg

-Jeff

[tomaco1]

Wrestled with the dash for Days! Finally took the whole thing out. should of done that in the first Place!!!!!


The old 110 style A/C- heat are now Gone.
Dash and how I have to get around now!

[JimC]

Why do I suspect you paid more for the tri bike than you did for the truck...

:grin

[tomaco1]

i wish, i'm sure its worth more!

[JimC]

Hey, since you have your dash out, why don't you order some cans from towerpaint and paint the area behind the dash Keswick green? It will look much better than masking later. Plus it makes you commit!

[tomaco1]

I was thinking that today! t would be a cool way to see the Keswick also.

[JimC]

mmm, greeeeen

[cellulararrest]

and maybe some dynamat or other soundproofing? I'd like to take my dash out to do that and cut my heater hole bigger.

[130Tdi]

Hey, since you have your dash out, why don't you order some cans from towerpaint and paint the area behind the dash Keswick green? It will look much better than masking later. Plus it makes you commit!
I was thinking that today! t would be a cool way to see the Keswick also.Funny you should say that Jim. While we had Cabell's truck apart he painted both the engine compartment and behind the dash of his 110's bulkhead Kent Green Metallic and clear coated it as well. Rover never offered Kent Green on the Defenders so he will be unique. Try picturing a tdi 110 pickup with a tan hood over the loadspace & Boost alloys in this green. Should look great.

Here's a picture of Cabell fitting the lower dash tray that catches the bulkhead color.

http://dividingcreekroverimports.com/yahoo_site_admin/assets/images/cabells_jan09_002.33102444.jpg

[JimC]

It looks a lot like willow green, but nevertheless, I think it will still look great if he leaves the door tops, sides, windshield frame and roof sandstone.

[TDI Guy]

Nice...

[evilfij]

I like the roan brown. Am I the only one? It looks like a pink panther.

https://www.expeditionexchange.com/tamiya/indexmain.shtml

[karlusmagnus]

I like the roan brown. Am I the only one? It looks like a pink panther.

https://www.expeditionexchange.com/tamiya/indexmain.shtml

Or go all out ... the pink panther itself ...
http://www.flickr.com/photos/si558/2759951117/

[tomaco1]

Its not PINK!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!


On another note, I thought I was getting close, until I went and saw TDI's truck today. That thing is unbelievable!

[discotdi]

Looking good Tom.when you are done it will be one heck of a truck>

[tomaco1]

New Dash Is in!
Jim the Radio holder looks Good, covers all the wires great, will hold gauges very shortly.
The Speaker Grills and spacers came in very handy also.

[JimC]

thats hot

[dave_lucas]

Nice steering wheel :pimp

Been trying to find one for my 90 :)

[tomaco1]

Ebay UK

[130Tdi]

Vent controls ? or does this bulkhead not have the vents ?

[tomaco1]

No Vents, I was debating them, but they seem they would be more of a pain in the A#$! I get enought water in the truck already.

[AmityD90]

Looks good Tom!
I kinda like the color it is now. Very unique around here.
Anyway, it looks like you've got alot done, but it looks like
you have a lot more coming :).

Looking forward to seeing more!

Gery

[GYM]

I like the roan brown. Am I the only one?
No. I like the roan brown, as well.

[golden747]

yea. you're dumb if you change the color. u want 2 sell it?

[woldd90]

yea. you're dumb if you change the color. u want 2 sell it?I disagree... Paint it. I plan on painting my SW Zambezi silver in the Fall.

[tomaco1]

Gauges are just in to see how they look, No sense hooking them up until the engine goes in.

I'm thinking: Engine Temp, Boost, Tach, Speedo (left to rt like the gauges)
Oil Pressure, Fuel, Volts. (In the Center)

whats the trick to getting the lights out of the gauges

Follow-up Post:

I disagree... Paint it. I plan on painting my SW Zambezi silver in the Fall.

If your going Zambesi Silver, have TDI send you a current picture of his, that silver truck and the black wheels,flares and top, look unbelievable. I haven't seen a lot of 90's, especially the ones that belong to the member here, but that is the nicest truck I have ever seen.

[JimC]

Personally, I'm not really into boost gauges, but I think an EGT is indispensable.

And, don't worry, I'm not offended that you don't think my truck is the nicest :grin

[tomaco1]

I'm a Black/grey/silver guy

[JohnsD90]

How did you get '85 registered its only 24 years

[JimC]

It was brought in during the 80's when it was legal. Import laws changed in 89 or 90.

[130Tdi]

I have pretty much the same setup. In the binnacle I have egt,fuel, coolant temp. In the center dash/radio box I have from left to right: tach, boost, oil pressure. I don't see the need for a volt meter on a diesel.

[tomaco1]

thanks for answering that Jim, because i had no idea. all i knew was that dmv registered it

[tomaco1]

Did the mods to the clutch/flywheel housing, and its all bolted up.
Sorry about all the questions.
All it took was a $40 counterbore bit and 20 ?'s

[dave_lucas]

Will you hurry up and get this thing installed already...




I am dying to hear how it compares to your current setup as I have a 200 sitting here and my 90 will be here soon.

[tomaco1]

I'm at the will of the students and their teacher.
Remember, I'm going froma 4cyl gas, so it should be a huge step up(I hope) The truck is torture now.

[tomaco1]

Fired up the engine Today, fired right up, just a quick puff of smoke and that was all.
One student did get covered in oil, oil cooler line came loose.
Now its time to take the truck a part.

[cabell]

Congrats Tom, new oil cooler lines went out to you on friday.

[tomaco1]

got them today, many thanks

[TDI Guy]

Cool... I fired up my 30 yesterday as well.... Its a great sound and feeling when you first start it up.

[tomaco1]

Engine should be out tomorrow. Wings and hood are going in for paint, I've decided to go white to match my doors.

Follow-up Post:

Does anyone know what color white the Doors are that came off the 2007-2008 trucks in Alabama?

[discotdi]

you can probably go to LR UK and just look up what white LR is using now. Maybe Chawton or Alaska white. That is what's on the 07 08 LR3's etc. What are you going to do with the 2.5 petrol eng?

[tomaco1]

The engine is out! Dam Easter Break, no work for a week.
Sorry Todd you can't have the 2.5 back, its sold already.

[discotdi]

Well, that is a sweet little engine. will be great in a series truck.

[rover4x4]

I disagree... Paint it. I plan on painting my SW Zambezi silver in the Fall.


are you going to take the truck apart?

[tomaco1]

Got some sweet new doors for the truck, and since they are so perfect I've decided to paint the truck to match, Chawton(sp) White. Also got a Wind Screen Frame , so C white it is.

Some opinions of hood blackouts, I don't want the whole hood to be white, so I'm going with some type of black on the hood.
I'm leaning towards some carbon weave black decals I found, I know its a bit "Fast and Furious" by I am a bit of a carbon freak.

[Ren Ching]

I never understood the carbon "look." If it is actually Cf that is great. But carbon look decals and the like are silly. But if you like it go for it and who cares what others think. keep in mind whatever you use for a hood blackout should be matte or flat finish if it is to perfrom its intended purpose.

As for functionality, at least the check plate pieces provide some added rigidity and protection from people like me who like to walk on bonnets and fenders and put tools and other items on the fenders while I am working.


Got some sweet new doors for the truck, and since they are so perfect I've decided to paint the truck to match, Chawton(sp) White. Also got a Wind Screen Frame , so C white it is.

Some opinions of hood blackouts, I don't want the whole hood to be white, so I'm going with some type of black on the hood.
I'm leaning towards some carbon weave black decals I found, I know its a bit "Fast and Furious" by I am a bit of a carbon freak.

[tomaco1]

I had the flat black one that I had to peal off to paint the hood. If I could fine a source for that I would go for that instead. If CF a misprint for the Checker Plate? or something else?

[TDI Guy]

Tom, were the doors you got the new style ones? I have a pair as well and the paint was basically exactly the same as the Alpine white. Next to the freshly painted Alpine white it was the same.. I did not take chances though and repainted the new doors anyway...

[tomaco1]

They were off a 2006 110 td5 according to the sticker on the wind shield, and it said Chawton white solid.
I assume they are the new style dooors, but Safari rovers ad says they changed in 2007?
I also assumed the wind shield frame and the doors were off the same truck, or at least batch of trucks.
I also couldn't see the diff between Chawton and alpine, there was an alpine truck where I picked them up.

[tomaco1]

Engine is in, but my main mechanic just got suspended for the rest of the week for fighting.
Fenders and hood are in the paint booth. I like the white.
My powder coater just offered to redo my wheels black to match the bumpers and sliders. very tempted.

[evilfij]

Replace your shock towers.

Ron

[tomaco1]

What would be my best option for new ones?


Theres a set of 2" lower towers in the for sale section, what else would I have to change to make them work?

[Ren Ching]

you would need a 2" lift and 2" longer bumpstops

I just cleaned mine up and painted them. well, the one that was bad anyway. they aren't hard to change out.


What would be my best option for new ones?

you would need a 2" lift and 2" longer bumpstops

I just cleaned mine up and painted them. well, the one that was bad anyway. they aren't hard to change out.


Theres a set of 2" lower towers in the for sale section, what else would I have to change to make them work?

[cgalpin]

Wow your truck is getting a nice makeover. Why not pull the headlight assemblies and get paint behind them?

[tomaco1]

I'm at the will of the Autobody teacher and his students.
Also I figure the more I take apart the less likely I am to find everything.

[tomaco1]

There was some down time in the engine install class, so I push it over to the Autobody class. I only have 3 weeks to get er done!

Kudos to Ron for suggesting that I needed new front shock towers, I thought they looked fine, but what do I know. The rush under and inside was pretty bad, scraped and treated the rush and started to install the Equippe Towers I got from Dale. Wanted to finish , but decided to treat the rust completely first.
Question: Do I need to put something between the Aluminium and the Frame?

I am more concerned now about the reaction between the two metals due to the fact that a friend Aluminium wheel was so stuck on the steel rotor, that it had to be drilled, tapped and finally beat with a sledge hammer.

Finally got some keeper seats! A little Star Tracky but they are crazy comfy and mount perfectly on a flat surface.

Also have included a pic of my backup ride for when the 90's laid up.

[dave_lucas]

Tom,

If possible you should have them remove the badges, lic plate light and the rear tire carrier.

I would also remove the little windows in the rear, the are really easy to remove (1 min with a razor blade) and then replace with a new gasket after the paint is applied.

I understand that you are having this done at school so your hands are kind of tied on some things but that is 30 min worth of work that would make a huge diffrence.

[evilfij]

"Question: Do I need to put something between the Aluminium and the Frame?"

Are the equipe ones aluminium? I assume that is what you are talking about. It surprises me that they would make them out of aluminium. I would put some silicone or cut a thin sheet of rubber into a gasket, but I don't think it is necessary, but it will prevent corrosion ruining the appearance of the shock towers.

If you are talking about somewhere else, the answer is whereever aluminium and steel meet, you want to isolate them with silicone, rubber gaskets, rubber washers or whatever you can to avoid corrosion.

Also, x2 on what dave_lucas says above.

Ron

[tomaco1]

I just assumed they were aluminum, but they were kind of heavy.The badge and the light will come off, i just have drill some rivet and ran out of time yesterday.
Is it worth taking out the small rear windows, cause there is no way I can take out the sides.
Thanks

[dave_lucas]

Is it worth taking out the small rear windows

It is more than worth it, you should be able to remove them in under 2 min per side.

The reason I am saying that is...

It is hard to prep the area properly with the gaskets there and the paint might start to flake / pull up next to the gasket or the gaskets might shrink (or change) in the future and expose the brown paint. Since you are changing the color this would look really bad if the paint started to flake and it was brown.

The best option is to remove everything you can when you change the color but I understand that your hands are tied to some extent. This is an easy thing to do that will only cost you some new gaskets and a few mins.

FYI when I remove windows that are held in with a gasket I get a sharp razor knife and cut around the middle of the gasket and the window will pop out easy. If your gasket is the type that has a rubber insert in the middle pull it out and see if the window will pop out, if not then you cut the gasket.

[evilfij]

Also, if the gaskets look good you do not have to cut them. They are two pieces the main gasket and a strip in the middle which holds the window in place. Pull out the strip and then carefully push the window through the opening if the gaskets are still good. George sells the gasket for $2.50 a foot new. I would also paint the rear door seperately.

[JimC]

No way you can take out the sides? You just pull the weatherstrip and drill the rivets. Might take an hour to do both. You'll get better paint if you do it, and its a good opportunity to replace the felts.

Follow-up Post:

And I've got the tool to reinstall the rear and alpine windows.

[evilfij]

BTW I see the towers in a picture I missed and there is no need to put anything between the frame and the tower (other than some paint to prevent rust on the frame) because the towers are cadinium plated steel.

[dave_lucas]

one last thing and I will stop making work for you / students :grin

Remove the rubber door seals around the front and rear doors rather than masking them. They are super easy to remove and only take a few mins to remove / replace.

[discotdi]

Tom,

If you need a mechanic while yours is suspended I know one, GRANTED HE DOESN'T KNOW JACK SH**T ABOUT DIESEL ENGINES!
Also the Nittos would look sweet on your back up ride.

[tomaco1]

Many thanks, I'll look at all the windows on Tuesday. The door seals I was going to do, but forgot. and the rear door is pretty much junk, so I will replace it. The Tailgate I got is already white. Keep the suggestions coming, they keep me honest, and stop me from cutting corners.
Thanks

[dave_lucas]

the rear door is pretty much junk, so I will replace it. The Tailgate I got is already white.

If you are installing a tailgate you will want to remove the rear door and hinges. If you are using a drop down it will not use the hinges and if you are going to do a NAS swing out the hinges are in a diffrent location.

If I remember correct you also have a front windscreen that is already painted white correct? If that is the case and you are planning to use it the best thing you could do at this point is just remove the top.

You are going to have to undo the front bolts anyways and it would make it easier for them to mask / paint the truck.

If it were me here is what I would do

Remove the top and windscreen (and windscreen hinges) take the sides of the top home in your daily driver and remove the rear windows and side windows at home. Take the sides back in and have them painted when they paint the truck.

That way the insides of the top sides will be painted and if you remove the top someday you will not have brown cappings and it will not look like a quick maco paint job.

It is a little more work but it will add value to your 90 where a short cut on paint will take away value

[evilfij]

Top you can get off in under an hour and into three pieces in under two hours.

[dave_lucas]

Top you can get off in under an hour and into three pieces in under two hours.

and he already has to remove the bolts in the front to replace the windshelid frame and that is most of the bolts for the top.

[dave_lucas]

You still out there Tom? Did the hardtop fall and crush you or a student put a cap in you for making them work too hard :)

[tomaco1]

I'm in a bit of a holding pattern, Its looking like it will be a bit ruff! I'm short on time.

[dave_lucas]

Just give the students detention and make them serve it in the shop working on your 90 :grin

[TDI Guy]

I almost have the rear door done for you Tom...... next week for sure.

[tomaco1]

Great, Thanks Randy. (No Hurry)
Painting try #2 today, keeping fingers crossed.

[tomaco1]

She is white and looks great, paint job is not perfect, but it still loooks great.
I got the oil pressure sender on usin the 10x1 Tadapter from VDO.
I tried to take your advice about removing the top, but I was denied by the Auto Body Teacher.
I will probably redo the top while its off this summer.

[RiftRover]

Tom,
I like the NAS lights, thinking of doing that on my truck. What did you have to do to wire them? Did you keep the NAS plug in connectors?

[dave_lucas]

I really like the wheels with the white paint :pimp

The NAS lights are a nice touch as well, I thought about adding them to my 84 but purchased a new set of the stock stock ones.

White will be nice since you have no A/C :)

Oh and did you decide what you are going to do for a rear door?

[tomaco1]

Rift, I found a place that had the plugs that worked with the NAS lights, and wired them up. They were a little pricey, and a bit of a pita, but once hooked up they worked well. I also found some rubber boots in the hardware store to waterproof them a bit.There is a good write up someewhere, I'll try and find it

Dave, I have the tailgate, and was still hoping to get the swing down door top from you. I'm also getting a SW door from Randy so I'll have both.

Follow-up Post:

http://www.nicksjungle.co.uk/Fitting%20NAS%20lights.html
Light writeup
Follow-up Post:

http://www.vehicle-wiring-products.eu/VWP-onlinestore/home/homepage.php
site for the plugs, I got the lights from George at RDS

[dave_lucas]

Dave, I have the tailgate, and was still hoping to get the swing down door top from you

I have 2 of them one POE style and one series style, I am just trying to decide what one I want to use then I will let you know.

Oh I dropped off some of the parts for the liftgate at the galvy place this week so they will both come with some fresh galv bits :grin

[evilfij]

Looks good. When you take the top off you can drill out the rivets holding the cappings and send them to be galvanized. That will get rid of the mismatched paint on the cappings.

[bjf]

What did you paint around the gas cap with? Looks good

[RiftRover]

Thanks for the info Tom. I love the black wheels as well, I have a set of deep dish alloys that I am planning to have powder coated black soon.

[tomaco1]

its just crap paint, I have to redo it soon. The gas cap, i actually sprayed with the rubber tool coating in black, which worked out great

[sven95lwb]

Hey Tom I was nice to meet you the other day. That 2.5 will be put to good use in Stuarts series hybrid.

BTW, your truck looks great in person.

[tomaco1]

Hey Sven, Thanks for the compliment, it is a tad rough, but I do love it. It seems I may see you friend in Smithtown this summer. Still lots to do.

[tomaco1]

She runs, great actually! Now I just have to iron out the clutch.
And as for the reason she wouldn't run? I'll never tell!

[evilfij]

What is wrong with the clutch? If it is stuck, put a tow strap on a tree and drive off with your foot depressed on the pedal. It will free itself.

[tomaco1]

I think it just needs to be bled better. The pedal stays down.

[evilfij]

I think it just needs to be bled better. The pedal stays down.

Install a proper clutch return spring.

http://www.d-90.com/forum/showthread.php?t=19153&highlight=clutch+spring

[tomaco1]

I tried to follow that post? So is it spring or no spring? And if spring, which one.
Drove the truck today, its awesome, one fender is on many more parts to go.
Another bled solved the clutch, and taking the t/c out of Neutral!

[evilfij]

Put on the fat spring from the pedal to the top of the bulkhead footwell.

[tomaco1]

Where can I get one?

[evilfij]

Go to the roversdownsouth link in the other thread. It is the fatter of the two springs.

[tomaco1]

Will do, thanks Ron.
George said I shouldn't need it, but it does seem pretty soft.

[evilfij]

Tell George to sell you the parts you ask for and if not I have 9 spares (don't ask why .....).

Ron

[tomaco1]

http://www.roversdownsouth.com/images/series-brakes/Springs.JPG (javascript:openWindow('images/series-brakes/Springs.JPG', 'Rover', false, 685, 530))Is this it on the top/left?

[evilfij]

The fat one. Top left.

[tomaco1]

Its coming together nicely! Drove it around the parking lot, it is a totally different truck.
Some down Shifting is a little rough, but it seemed to stop after a couple of laps around the lot,( hoping its just because of the long time sitting) and I'm going to put synthetic in the tranny Monday, which really helped my old lt77
I finally got the oil cooler lines worked out, Another $150 bucks, on top of what I payed for them.


Ron If you have an extra spring, It'd be great if I could buy one from you, George is out.

[cgalpin]

Hey Tom, how do you get involved in one of these school shop programs?

[tomaco1]

Its top secret!


Actually in NY state, you can get your foot in the door with a couple years work experienc and the willingness to go back to school and get your masters in 7 years.My situation is a little different, I'm a Special Ed teacher, I work as a Dean of sorts.
Check with the VA state ed department and find the requorements for vocational teachers.In NY the jobs seem to be a well kept secret. They are still screwed up in this economy, but when we interview we get 2 or 3 applicants, where any other school job would probably have over 100.

[evilfij]

I want to be a shop teacher when I retire.

Ron

[evilfij]

PM me your address and I will send you a spring.

Ron

[tomaco1]

Its looking kinda white!

[evilfij]

Lookin' good. If I forgot to PM you, your spring is in the mail.

[budz]

Tom,

Are you going to MAR this year?

Sal

[tomaco1]

As long as all tghe bugs are worked out? And I have to check the date.

[dave_lucas]

post some pics / details on the tire carrier setup please.

[tomaco1]

I will, but its an off brand type I got from DAP.
Did you put your new hinges on? I have it on like I was told, but it still seems wrong

[dave_lucas]

tailgate hinges or front door hinges? I have the rear tailgate hinges installed, the front doors will take longer as I am in the middle of moving my house and shop

[tomaco1]

Dave, some tailgate pics, its still a little rough and I still have to do the latch.

[budz]

Very nice, Tom...

[JohnsD90]

That looks great.
Now with this rebuild to what looks like NAS specs would this fetch NAS prices.

[tomaco1]

Thats not what I am expecting, but I guess you never know!

[JimC]

With a diesel engine and lots of great parts, I wouldn't at all be embarrassed asking 20 or more for it.

[Ren Ching]

There aren't enough layers in my Nomex suit for me to answer that question :)




Now with this rebuild to what looks like NAS specs would this fetch NAS prices.

[tomaco1]

After 3 days of scrambling to finish, I got it close enough to take out on the road.
It runs great, its much peppier, and sounds much meaner ( partially due to the fact that there is no muffler yet)
A lot of loose ends to tie up including the muffler.
Another giant bonus is that it fits in my garage. with 1" to spare.

[bjf]

Looks great. Almost too good. I don't like non NAS trucks to look this good.

[dave_lucas]

Sure is a big change from where it started :eek:

You planning to run topless for the summer?

[tomaco1]

I'm going to try it and see how I like it, and how many times I get caught in the rain.

[JohnsD90]

I'm going to try it and see how I like it, and how many times I get caught in the rain.
Id suggest to take the roll bars off kinda looks akward, or just take the external cause it has no mounts on the top.
P.S. what's that hole in the crossmember, i've seen it on other ROW trucks whats it for?

[tomaco1]

The roll bars are connected.and I figure its a bit safer with them on.
If its the same hole I'm thinking its for a trailer plug.

[cgalpin]

Got any close ups of where the exo cage bits meet the roll bar?

[JimC]

Looks great Tom. Leave the cage on it, it doesn't look awkward, it just looks like a cage, and i'm sure rolling with it is better than rolling without it. Of course, rolling is not advised...

[130Tdi]

Looks great Tom. I like the white much better than the Rowan Brown. What did you do with your old brown doors ?

[tomaco1]

Thanks, I'm at the muffler shop as I type this.As far as the doors, the guy who bought the engine bought them.

[TDI Guy]

Looks Bad Ass. Tom. I have your rear door ready as well. Let me know when you want to stop over. I have to take some final pix of the S/W to post. Its all done except for some final touches on the custom built sliders...

Randy

[tomaco1]

Thanks Randy, I'll let you know when I can get to you. Hey if you know anyone that needs those 2 muffler parts I got from you let me know, I had mine done today, and we didn't use it.

[dave_lucas]

Tom,

Did you fit the strickers or did your students?

Just wondering how hard it was

[tomaco1]

I did it, and it was a pain in the ass. I have to redo them, but I think part of the problem is that you need to shave off a bit of the plastic spacers.
I also couldn't get the existing holes to work, but if you measure more carefully than I did they might work.

[discotdi]

Looks great. did you put A/C in it? you know it is hot down here in GA!

[tomaco1]

Took the truck on a minor road trip this weekend. What a difference, its like a new truck. Haven't done the mileage yet, but at 200+ I still have a 1/4 tank left. I was usally putting gas in at 150 miles, with the old 4cyl gas.

I wanted to thank everyone for the help, knowledge, and all the parts I got through this site.(not that I'm done asking ?'s or buying parts.





A few more pics.
Sorry Todd, the trucks staying in NY.

[JimC]

It looks really good Tom. I bet you're happy you bought all those sweet parts. I'm sure you're going to have a great time with this truck.

[dave_lucas]

So what you are saying is that I should get off my lazy butt and install that 200TDI in my 90 rather than letting it sit in the corner :cool:

Must have been a nice feeling to take a road trip and enjoy it after all of that hard work

[tomaco1]

I would say put it in, it was a huge difference for me. But I'm not sure how the 2.5 petrol compares to the 2.5 NA performance wise. Driving it was a huge payoff, the last week was a pain in the ass, but getting it on the road for the 4th was great.
On the downside I did notice the large amount of tools who still have Defenders in the Hamptons.

[dave_lucas]

it was a huge difference for me. But I'm not sure how the 2.5 petrol compares to the 2.5 NA performance wise.

My understanding is that a 2.5 petrol has more umph than a NA 2.5 diesel.

you need to make an avatar that flips between the old brown pic and the new white version

[tomaco1]

1st major problem is that the windscreen rattles like a bitch.
fixed it by running a 1.5 inch piece of aluminium from windscreen to one of the spots were the rollbar ties together. Made a bi difference. I got the idea from a forsale post on the ST piece that seemed to go in the same location.

2nd problem was covering the truck when it rains. order a semi-custom version of a pickup bed cover for the rear and am going to have a bikini made. will install this week.


Turbo boost gauge was teed off the wastegate hose for the time being, I knew it would be a while before I drilled and tapped the manifold.(scares me a bit)Seems to work just fine.

By the way: 1st 2 tanks 24MPG around town, so much better than the 12mpg from the 2.5 petrol

[airbornrover]

There is a thread here with the Badger talking about selling a line of covers that are similiar to the ones that you see on jeeps that dont have there tops on, like a fitted rain cover. Of course the Badgers is of superior quaility and design. So when you park it all you do is throw it over and attach it where needs to attach and your good to go.

Calling the badger man is the title of the thread.

[AmityD90]

2nd problem was covering the truck when it rains. order a semi-custom version of a pickup bed cover for the rear and am going to have a bikini made. will install this week.
lTom
Looks awesome!

Top Stitch in Patchogue might be able to put something together for you if you haven't gotten to this.
Reasonable prices and they've done nice work for my families boats.

[tomaco1]

The Torneau was a bust so I found a company that makes pickup bed covers and had them modify one for me.
4 Screws and it will come right off when I have to put the SW top back on. As you can see in the picks, I put the drop curtain on which is supposed to work with the ST and SW but it doesn't reall seem to fit to well.(Any Ideas)
I'm obviously still sorting out some Bikini issues, thats a Jeep Bikini I just put on if it looks like rain.

[rover4x4]

what rock sliders are those?

[tomaco1]

Equipe I had re-powder coated

[JohnsD90]

Tom,

Hows this coming, the SW roof on yet, is it an older ROW roof or newer/NAS.

[tomaco1]

Thr SW top is going on this week, its a ROW ribed roof (for her pleasure) I just got the new seals.

[JohnsD90]

Thr SW top is going on this week, its a ROW ribed roof (for her pleasure) I just got the new seals.Nice, i like the way that roof looks. Should look like it just rolled out of Solihull in a 85. keep us posted.

[dave_lucas]

Tom,

Document the install of your new rear disco axle, I am planning to do the same and would like to know what parts are needed and what if any modifications need to be done :)

[tomaco1]

The Disco Axle transplant began today! I got all new bushings, and the a-frame swivel.

One minor problem, the teacher told a student to cut the ears off the swivel so we could press it out, but he went a little overboard and he cut right through the A-frame. Luckily I have the backup from the Disco.

I went with the OEM bushings after much research.

The Disco Axle is ready to go, new pads, cut the rotors, etc. They tried to sell me a shim to quiet the rear brakes? Is this necessary?

The Old 90 axle is just about out, no school tomorrow, dam election day!

[mightymg]

I thought the 90 and the disco axle was the same, whats the difference, I put my disco axle under my defender,and vice versa?

[dave_lucas]

Toms 90 is an early one with 10 spline and drum rear brakes, the swap to a disco axle will get him a 24 spline 3rd, axles and disk brakes.

[mightymg]

Toms 90 is an early one with 10 spline and drum rear brakes, the swap to a disco axle will get him a 24 spline 3rd, axles and disk brakes.
AHHH IC

[tomaco1]

What? AHHH IC?

[JohnsD90]

ahhh, i see

[tomaco1]

I thought it was something like imho. ahhh, i see

[tomaco1]

Back On the road today, the disc brakes make a huge difference. My drums were a mess so my braking improvement maybe better than normal, I've been pumping my brakes since July!

Even better than the brakes is the difference the new bushings make, so many mystery noises are gone, I can't wait to do the front. The whole truck seems so much tighter.

A few observations while swapping the old drums to the 97 Disco rear.

Bushings are a huge PIA to get out! Burnt cut and chiseled out of the upper Aframe and trailing arms.
The Aframe swivel was a huge pain also, biggest tip I got was to cut the ears off and press it out 30k+ on the press. Funny story about cutting the ears off the swivel, teacher told one of the students to cut them off, teacher got busy and stopped paying attention and the student cut all the way through the aframe. Luckily I had the extra from the Disco and it was the same.

As far as the braking, just like dieseljim said, its great without changing the master or adding any proportioning valve.

[dave_lucas]

Did you have to do anything with the brake lines?

[tomaco1]

I used the ones from the Disco axle which meet at the diff, I had the stainless from there.

[tomaco1]

Heres a pic with the Hardtop on.

Tach is working thanks to a new alternator from RDS. (I used the rough estimate technique)

New rear bushing made a huge difference in ride quality.

Rear disc brakes are a huge plus.

I can't get the Oil pressure to work, I put a test light on the sender with the engine running and nothing happens?

I also read after the fact about changing the Soft line when doing the Clutch Master and Slave, learned the hard way, waiting for a new slave as I type.

Front axle and bushings are the next project.

[TDI Guy]

Looks great Tom. Check your PM's

[JohnsD90]

I can't get the Oil pressure to work, I put a test light on the sender with the engine running and nothing happens?

.
Thats because land rovers dont have oil pressure, its a constant leak. ;)

Looks Great.

[don]

Wow - you did a lot of work on that rig. Great job with it. And it sounds like you know every inch of it.

Sunset pic looks very cool but can't wait to see detail pics when you get a chance. :D

[draaronr]

Man Tom that thing looks great, those kids in shop class did a bang up job :)

[mgreenspan]

Done the front axle yet? I'm curious about any issues you may run into. I've got my Disco's housings with ARBs, 4.11s, ashcroft shafts etc and want to swap them to my 84 90. Your truck looks great.

[tomaco1]

I haven't done it yet, I'm waiting on a few things, but I heard I needed the radius arms from the Disco also.

[TDI Guy]

I haven't done it yet, I'm waiting on a few things, but I heard I needed the radius arms from the Disco also.

Kevin, No you do not.... they are all the same... A Disco 1 front housing is the same as the d-90 one

[evilfij]

Kevin, No you do not.... they are all the same... A Disco 1 front housing is the same as the d-90 one

No, they are not. Early radius arms are "narrow" and later ones as "wide". NAS 110s have narrow arms as do a lot of grey market trucks. I express no opinion about running narrow arms on a wide housing, but vice versa they do make contact.

[TDI Guy]

No, they are not. Early radius arms are "narrow" and later ones as "wide". NAS 110s have narrow arms as do a lot of grey market trucks. I express no opinion about running narrow arms on a wide housing, but vice versa they do make contact.


I was not aware of this.... I stand Corrected then.. :angry

[evilfij]

No problem.

Ron

[tomaco1]

Would the ones from a 97 disco be the wide or the narrow? I haven't measured yet, I'm just holding on to both(all 4 actually). I was hoping to do the bushing on the disco ones I have laying around, to save time when I swap them.

[dave_lucas]

97 is wide

Tom, if you need some I have a spare set that you can have

[tomaco1]

Thanks for the offer Dave, but I have the 97 axle and arms from the Disco

[mgreenspan]

Aight, so a disco rear disc axle housing setup will swap right over to a 90. Anybody know about if it'll do it to a 110 with a sals rear end?

[dave_lucas]

You could swap it but the sals diff is wayyy stronger than the rover diff so you should keep the rear sals in there. If you want rotors instead of drums you can swap in new rotors.

Since you are in the UK you could also go to the breakers and buy a sals that will come with the rotors from the factory but I think either way you should keep the sals in a 110.

It’s pretty much a Dana 60 so it is strong and when / if you decide to buy gears or a locker you can use Dana 60 parts and save some money compared to rover stuff.

[mgreenspan]

I'm aware of the strengths of the sals. It's a 24 spline set-up from my 98 Disco with ARB GBR axles and 4.11s so I'm ok with swapping down from the sals. The idea is to just get the shit off the Disco and onto the 110 so I can completely scrap the remains of the Disco and then rebuild the sals into equivalent to the Disco set-up and have a toy to play with then have the remaining rear 24 spline to throw onto the 90 down the road for funsies.

[evilfij]

Since you have a 90, not a 110, the disco rear will bolt right up. To fit a 90 axle to a 110 (or vice versa) you need to account for the 1in extra diameter in 110 rear springs by moving the spring plate (drill a couple more holes and/or reposition captive nuts ie no big deal) and fitting the proper spring plate. You will have to use a shorter driveshaft with a sals than a rover rear axle due to pinion length.

[mgreenspan]

Word. Thanks for the input. Originally the stuff was going onto the 110, but it's received some dents on the front wing so it's going to become the offroader... onto the 90 the parts shall go.

[tomaco1]

Cheapest/Best improvement yet. For all us Guys with the Older trucks, fell like your driving a much newer truck every time you look behind you!

Disco I rear-view Mirror!

Know if I only knew what the three wires were for?

[mgreenspan]

Alright. Disco LHD front axle housing to a RHD 90. What was the verdict on ease and extra stuff I'll need. Deployed now but going to take this on when I get back and putting all the Disco goodies onto the 90.

[tomaco1]

My truck is LHD so I can't help you, plus I've only done the rear so Far.
Stay Safe

[mgreenspan]

Roger that. I'll report back later in August once I've figured it all out. Thanks.

[tomaco1]

Finally got a chance to take the truck somewhere besides the beach. It wasn't MAR, but it was close to home.
Dog wasn't crazy about it though.

[AmityD90]

Finally got a chance to take the truck somewhere besides the beach. It wasn't MAR, but it was close to home.
Dog wasn't crazy about it though.

Is that Calverton path?
Truck looks great Tom!

[tomaco1]

Is that Calverton path?
Truck looks great Tom!

Its Montauk, at the end of the stretch. Up by the overlook.